A PROJECT REPORT ON

SCALED BIO GAS PLANT

Submitted in partial fulfilment of the requirements for
IC ENGINES COURSE
In
MECHANICAL ENGINEERING
By V SEM students

DEPARTMENT OF MECHANICAL ENGINEERING

(Accredited by NBA, 2014-2019)
B.M.S COLLEGE OF ENGINEERING
(Autonomous College under VTU)
BENGALURU - 560019
Nov 2015

DEPARTMENT OF MECHANICAL ENGINEERING

(Accredited by NBA, 2014-2019)
B.M.S COLLEGE OF ENGINEERING
(Autonomous College under VTU)
BENGALURU - 560019
Oct 2015

This is to certify that the following students mentioned in the list

enclosed have submitted their project report in partial
fulfilment of IC engines course

Signature of Staff in charge

( Dr.RSK)

By:
1. Narendra Pandit S
2. Shyam Chafekar
3. Rhythm Agarwal
4. Tausif Ahmed M
5. Suraj Simha SG
6. Nitish Kini U
7. Pradyot Satyappanavar
8. Anup Kamath
9. Aravind Koti HR
10. Manish Suvarna
11. Prasidh N Kushavar
12. Prakhar Rawal
13. Rohit Anil
14. Nihal Verma
15. Shivakumar
16. Shreyas A Kunte
17. Dodda Manogna
18. Ayush Kohli
19. Pradeep Divatagi
20. Rahul Potdar
21. Udyanth Vaidya
22. MD Saif Ur Rahman
23. Mohammed Hussain C
24. Amith Joshi

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1BM13ME100
1BM13ME083
1BM13ME110
1BM13ME108
1BM13ME067
1BM13ME073
1BM13ME022
1BM13ME024
1BM13ME055
1BM13ME076
1BM13ME075
1BM13ME086
1BM13ME064
1BM13ME095
1BM13ME096
1BM13ME039
1BM13ME027
1BM14ME413
1BM13ME080
1BM13ME116
1BM13ME058
1BM13ME060
1BM13ME014

Introduction
The bio-gas produced from food waste, decomposable organic material and kitchen waste,
consisting of methane and a little amount of carbon di oxide is an alternative fuel for cooking
gas (LPG). Also, the waste materials can be disposed off efficiently without any odor or flies
and the digested slurry from the bio-gas unit can be used as an organic manure in the garden.
The major components of the bio-gas plant are a digester tank, an inlet for feeding the kitchen
waste, gas holder tank, an outlet for the digested slurry and the gas delivery system for taking
out and utilizing the produced gas. This project is also useful for students to have a hands-on
learning experience in constructing a Mini Bio-Gas Plant, using locally available material.
Bio-gas Composition
Biogas typically refers to a mixture of different gases produced by the breakdown of organic
matter in the absence of oxygen. Biogas can be produced from raw materials such as
agricultural waste, manure, municipal waste, plant material, sewage, green waste or food
waste. It is a renewable energy source and in many cases exerts a very small carbon footprint.
Biogas can be produced by anaerobic digestion with anaerobic bacteria, which digest material
inside a closed system, or fermentation of biodegradable materials.
Biogas is primarily methane (CH4) and carbon dioxide (CO2) and may have small amounts of
hydrogen sulphide (H2S), moisture and siloxanes. The gases methane, hydrogen, and carbon
monoxide (CO) can be combusted or oxidized with oxygen. This energy release allows
biogas to be used as a fuel; it can be used for any heating purpose, such as cooking. It can
also be used in a gas engine to convert the energy in the gas into electricity and heat.
During combustion of biogas containing siloxanes, silicon is released and can combine with
free oxygen or other elements in the combustion gas. Deposits are formed containing mostly
silica (SiO2) or silicates (SixOy) and can contain calcium, sulfur, zinc, phosphorus. Such white
mineral deposits accumulate to a surface thickness of several millimeters and must be
removed by chemical or mechanical means.
For 1000 kg (wet weight) of input to a typical bio-digester, total solids may be 30% of the
wet weight while volatile solids may be 90% of the total solids. Protein would be 20% of the
volatile solids, carbohydrates would be 70% of the volatile solids, and finally fats would be
10% of the volatile solids.
COMPONENTS

CH4 % vol
CO2 % vol
N2 % vol
O2 % vol
H2O % vol
TOTAL % vol
H2S mg/m3
NH3 mg/m3

HOUSEHOLD
WASTE

50 - 60
38 - 34
5-0
1-0
6 (approx. at
313 K)
100
100 - 900
-

WASTEWATER
TREATMENT
PLANTS
SLUDGE
60 75
33 19
10
< 0.5
6 (approx. at
313K)
100
1000 4000
-

AGRICULTURAL
WASTE

60 - 75
33 - 19
1-0
< 0.5
6 (approx. at 313K)
100
3000 - 10000
50 - 100

WASTE OF
AGRIFOOD
INDUSTRY
68
26
6 (approx. at
313 K)
100
400
-

Aromatic mg/m3
Organochlorinated
or organofluorated
mg/m3

0- 200
100 - 800

Physical characteristics

According to its composition, biogas presents characteristics interesting to compare with

natural gas and propane. Biogas is a gas appreciably lighter than air, it produces twice as less
calories by combustion with equal volume of natural gas.
TYPES OF GAS

Composition

PCS kWh/m3
PCI kWh/m3
Density
Mass (kg/m3)
Index of Wobbe*

BIOGAS 1
HOUSEHOLD
WASTE
60 % CH4
33 % CO2
1 % N2
0 % O2
6 % H2O
6.6
6.0
0.93
1.21
6.9

BIOGAS 2
NATURAL GAS
AGRIFOOD WASTE
68 % CH4
26 % CO2
1 % N2
0 % O2
5 % H2O
7.5
6.8
0.85
1.11
8.1

97.0 % CH4
2.2 % C2
0.3 % C3
0.1 % CH4+
0.4 % N2
11.3
10.3
0.57
0.73
14.9

(*The Wobbe Index (WI) or Wobbe number is an indicator of the interchangeability of fuel
gases such as natural gas, liquefied petroleum gas (LPG), and town gas and is frequently
defined in the specifications of gas supply and transport utilities.)
Various chemical process in biogas production
Acidogenesis, or fermentation, happens when acid-forming bacteria oxidize the simple
compounds formed during hydrolysis to create carbon dioxide, hydrogen, ammonia, and
organic acids.
Acetogenesis is the conversion of organic acids into acetic acid. Acetic acid is the main
ingredient in vinegar and is the food for the final stage of decomposition within the generator.
Acid-forming bacteria are fast-breeding and hearty, producing lots of CO2.
Methanogenesis is the creation of methane-producing microbes, or methanogens (singlecelled, nonbacterial microorganisms from the group Archaea). Methanogens combine
hydrogen and CO2 produced during the acid-forming phases to create methane. In contrast to
the acid formers, methanogens are slow to reproduce and extremely sensitive to temperature,
pH, and the presence of oxygen.
Rule of thumb for biogas production: A well-managed generator may produce
approximately its own volume of biogas each day. To put this in terms of energy production,
a bit of math is required:

A 55-gallon drum has a volume of about 7.35 cubic feet.

One cubic foot of methane contains 1,000 Btus of energy.

Biogas containing 60 percent methane offers 600 Btus of energy for each cubic foot.

7.35 cubic feet x 600 Btus per cubic foot = 4,410 Btus.

A typical gas cook stove burner might burn through 15,000 Btus of fuel per hour on
maximum heat. At this rate, a 55-gallon methane generator can potentially produce enough
gas in a day to supply the burner for about 18 minutes, allowing you to boil about 2 gallons of
water (assuming a 60-percent transfer efficiency between the energy in the flame and the
water in your pot).
This might be enough in some cases, but in a practical sense, a small family with modest
daily cooking needs will require the output of a warm, well-fed, 200-gallon (27-cubic-foot)
methane generator at a minimum. This much biogas represents about 16,000 Btus and offers
about one hour of cooking time, or enough energy to boil around 8 gallons of water.
The quantity and quality of methane you make depends on the nutrient value of the feedstock
and how well the microbes convert the available nutrients into methane. For practical
purposes, biogas production and quality are functions of your specific recipe and generator
management. Important things to understand about generating biogas are:

Construction of biogas extraction plant

The main components of biogas plants are:
1.
2.
3.
4.
5.

Bio waste dumping unit

Gas flow pipe
Non return valve
Gas collection tank
Outlet valve

1. Bio waste dumping unit:

This unit is the place where waste is dumped for synthesis of biogas. This contains removable
lid for dumping the waste and removing the residue at the end of synthesis of bio gas. It has
an outlet connected to gas collection chamber with a non-return valve in between, via a gas
flow pipe

2. Gas flow pipe

Gas flow pipe connects biogas dumping unit with the collection chamber. A non-return valve
is connected at the end of the pipe which is placed inside the collection chamber

3. Non return valve:

Non-return valve is basically a U bend in the pipe which allows flow of biogas in only one
direction. It does not allow water to flow back through it.
4. Gas collection Chamber

It is a weighted inverted cylinder with an outlet delivery valve on the top of it. The weight of
the cylinder is responsible for the production of pressure in biogas.
5. Outlet Delivery Valve

It controls the flow rate of biogas flowing out of the collection chamber.
Working of biogas plant

The model biogas plant is designed such that it uses no moving parts to collect and pressurize
the biogas. This type of plant can be used in both large scale production units and small
household systems. The plant basically consists of 3 systems, 1) Generation chamber 2)
Collection chamber 3) filtration unit.
Generation Chamber
It is a huge pit dug into the ground, in this various biomass are mixed with equal parts of
water and mixed thoroughly. The slurry need to breakdown anaerobically under the action of
various microbes. Thus the tank needs to be dug into the ground with channels to feed it
slurry at the lower levels. This slurry is then abandoned in the pit for 2 months, the biomass
decompose to release methane (CH 4), carbon dioxide, and hydrogen sulphide (H 2S). Among
these methane is the combustible fuel. The generation chamber is connected to the collection
chamber via piping which has a valve. Thus the generation chamber is kept dormant for 2
months all the while the gas is slowly collected in the collection chamber by opening the
valve periodically.
Collection chamber:
Structurally this is made of two cylinders inverted onto one another, one of the cylinders is
filled with water almost to its brim while the second is inverted onto this with an opening at
its top so that it gets immersed to some extent. The top opening is then closed with the use of
a valve. The biogas is let into the tank with through a one way delivery valve which does not
allow water to flow back into the piping. The gas bubbles through the water and gets
collected into the air gap of the second cylinder. Because of the volume of gas collected the
top cylinder begins to rise, and in effect due to the weight of the cylinder the gas also
develops a pressure which is required. And since the gas is bubbled into the chamber there is
no chance of back flow. The gas can be harnessed by opening the delivery valve thus giving a
steady supply of pressurized gas, once the valve is opened and as gas begins to start flowing
out the cylinder begins to drop thus maintaining constant pressure output (i.e. equivalent to
weight of the cylinder)
The harnessed biogas is then used directly or loaded onto small cylinders depending on the
area of use , this can either be used for heating , cooking or in some cases to run engines
Bio Gas Purification
Worldwide, there are about 10,000 biogas driven cars and buses, plus an additional 3.8
million natural gas fuelled CSANR Research Report 2010 001 Climate Friendly Farming
Ch. 9 Compressed Bio Methane Page 2 vehicles, mainly in Argentina, Brazil, Pakistan, Italy,
India and the U.S. To help develop appropriate biogas purification technologies for farmscale anaerobic digesters, Washington State University evaluated various methods for
removing acidic impurities, and developed and tested absorption tower technologies for
application to a farm-scale anaerobic digester.
Purified biogas provides reductions in GHG emissions as well as several other environmental
benefits when used as a vehicle fuel. Biogas emits less nitrogen oxide, hydrocarbon and
carbon monoxide than gasoline or diesel, and engines fuelled by purified biogas are quieter
than diesel engines. Refuelling with biogas presents fewer environmental risks than refuelling
with gasoline or diesel, because it can be done at small units located at an owners home or
business, minimizing the potential impacts if leaks or spills occur. Feasible biogas

purification technologies exist for large-scale sewage and bio-waste digesters, and the
technologies for upgrading biogas, compressing, storing and dispensing bio methane are well
developed. If cost-effective methods for upgrading biogas could be developed for the farmscale, biogas purification could provide dairy farmers with revenue to complement electrical
power sales. This is especially critical in the Pacific Northwest, where low power rates have
prevented cost competitive power from farm-scale anaerobic-digesters, limiting total dairy
derived power. Engine conversion to accommodate biogas also represents a potential barrier,
but because biogas has the same properties as natural gas, it can be easily used by vehicles
which are configured for natural gas.
Methods of Purification of Bio Gas
1. Water and Polyethylene Glycol Scrubbing Process.
Process
Water scrubbing is used to remove CO2 and H2S from biogas since these gases are more
soluble in water than methane. The absorption process is purely physical. Usually the biogas
is pressurized and fed to the bottom of a packed column while water is fed on the top and so
the absorption process is operated counter-currently.
Water scrubbing can also be used for selective removal of H 2S since H2S is more soluble than
carbon dioxide in water. The water which exits the column with absorbed CO 2 and/or H2S can
be regenerated and re-circulated back to the absorption column. Regeneration is
accomplished by de-pressuring or by stripping with air in a similar column. Stripping with air
is not recommended when high levels of H 2S are handled since the water quickly becomes
contaminated with elementary sulfur which causes operational problems. When cheap water
can be used, for example, outlet water from a sewage treatment plant, the most cost efficient
method is not to re-circulate the water Polyethylene glycol scrubbing relies on the same
underlying mechanism as water scrubbing, with a physical absorption process that works
because both CO2 and H2S are more soluble than methane in the solvent. Selexol is the trade
name for one of the common solvents used for this process.
Advantages
The big difference between water and solvents is that CO 2 and H2S are more soluble in
Selexol which results in a lower solvent demand and reduced pumping. Removing H2S
beforehand is an alternative. The advantages of scrubbing are no special chemicals required
and removal of both CO2 and H2S. The disadvantages of water scrubbing are that it requires a
lot of water even with regeneration, as well as limitations on H 2S removal, because the CO2
decreases pH of the solution and corrosion to the equipment caused by H2S.
2. Chemical Absorption
Process in a Nutshell
Chemical absorption involves formation of reversible chemical bonds between the solute and
the solvent. Regeneration of the solvent, therefore, involves breaking of these bonds and
correspondingly, a relatively high energy input. MEA solution can be completely regenerated
by boiling for 5 min and is then ready for re-use. The advantages of chemical absorption are
complete H2S removal, high efficiency and reaction rates compared to water scrubbing, and
the ability to operate at low pressure. Because of these advantages, the process is commonly
used in industrial applications, including natural gas purification. The disadvantages are the
additional chemical inputs needed and the need to treat waste chemicals from the process.

Pressure Swing Adsorption

Process
Pressure Swing Adsorption (PSA) is a technology used to separate some gas species from a
mixture of gases under pressure according to the species' molecular characteristics and
affinity for an adsorbent material. It operates at near-ambient temperatures and so differs
from cryogenic distillation techniques of gas separation. Special adsorptive materials are used
as a molecular sieve, preferentially adsorbing the target gas species at high pressure. The
process then swings to low pressure to desorb the adsorbent material. The PSA process relies
on the fact that under pressure, gases tend to be attracted to solid surfaces, or "adsorbed". The
higher the pressure, the more gas is adsorbed; when the pressure is reduced, the gas is
released, or desorbed. PSA processes can separate gases in a mixture because different gases
tend to be attracted to different solid surfaces more or less strongly. If a gas mixture such as
air, for example, is passed under pressure through a vessel containing an adsorbent bed that
attracts nitrogen more strongly than it does oxygen, part or all of the nitrogen will stay in the
bed, and the gas coming out of the vessel will be enriched in oxygen. When the bed reaches
the end of its capacity to adsorb nitrogen, it can be regenerated by reducing the pressure,
thereby releasing the adsorbed nitrogen. It is then ready for another cycle of producing
oxygen enriched air.
However, during biogas purification, the adsorption material adsorbs H 2S irreversibly and
thus is poisoned by H2S. For this reason, a preliminary H2S removing step is often included in
the PSA process. PSA using zeolites or activated carbon at different pressure levels is an
effective method for the separation of CO2 from methane. Activated carbon impregnated with
potassium iodide can catalytically react with oxygen and H2S to form water and Sulphur. The
reaction is best achieved at 7 to 8 bar and 50 to 70 oC. The activated carbon beds also need
regeneration or replacement when saturated. The advantages of PSA technology are more
than 97% CH4 enrichment, low power demand, and low emission and removal of nitrogen
and oxygen. The main disadvantage of PSA technology is an additional H2S removal step
needed before PSA. Also, tail gas from PSA still needs to be treated.
Conclusion
Bio gas is an effective renewable source of energy which can be applied to various
applications, it is cost effective and can be implemented in many conditions. The low cost
factor of biogas makes it a very a popular system in rural areas, in urban conditions it can be
used as waste treatment plant which also produces usable methane fuel , the above mentioned
model is effective in a large scale and can be implemented